Reflector



Patented June23, 1942 REFLEc'roR James A. MoreheatLBuntington, W. Va., assignor to Samuel M. Dover, Chicago, lll.

`Application October 18, 1938, Serial No. 235,685

6 Claims.

'I'his application is a continuation in part of my application, Serial No. 67,881, led March 9, 1936.

This invention relates tooptical apparatus and, more particularly, to the portion of the optical apparatus which directs rays of light in the desired manner, namely, t the lens.

,The present invention is concerned, more spef Y ciflcally, with autocollimating reectors such as are used, for instance, on highways, and onautomobiles or other vehicles. The object of such reectors is to reect light from the headlights of an approaching vehicle backI towards the source with an amount of spread only sufficient to enable the reflected light to reach the line of vision of the driver of the approaching vehicle even though the light may strike thel reflector from various angles within a wide range.v With improved highways and consequent higher and higher automobile speeds it becomes more and more necessary to have such reflectors which are capable of reflecting a large amount of light for very great distances in a direction substantially parallel to the incident beam. The legal requirements in many instances are such that the relected light from the headlights of an approaching vehicle must be of a specified intensity to be clearly visible at a distance of three hundred feet or more. This necessitates a high degree of precision in the curvature of the reectorthereby, of course, increasing the cost of manufacture of useless in most instances, unless it is subjected to grinding or other operations to bring it to the requisite curvature. This defect becomes more and more serious as the size of the reflector button being manufactured is increased. It is one of the objects of the present inventionto provide a large reflector button of the above mentioned character, made in two stages, the first stage of which aims to form the reecting surface, or the surface which becomes distorted, to approximately but not necessarily quite the requisite shape, said surface having less glass than required rather than more glass. Therefore the surface must be built up to the requisite shape instead of having to be ground down to the requisite shape. 'Ihis unit, when quite-ho. but still solid, is placed ina mold and a layer of molten glass placed over it. A die then presses the layer of molten glass to the requisite shape so that the newl;7 added glass forms a thin lm which is fused to the previously formed reflector button and forms an integral part thereof. Upon retraction of the die, or cooling of the thin film of glass, the total amount of molten glass that is subject to change in shape is so slight that the change in shape of the finished reflecting surface is negligible and the surface cools to substantially the shape to, which it has been molded by the die.

Reflector buttons that are to reflect light in.-

dicative of danger should be of a red color,- ,since red is the accepted color for indicatingv danger. Red glass necessarily absorbs a good deal more light than clear transparent glass absorbs, hence tensity of the coloring are increased. In largel ".reector buttons. where there is an appreciable in the curvature of the reflecting surface will result in a diminution of the reflected light in the desired direction. At a great distance this diminution is so great as to render the reector unsatisfactory, even though the deviation from the correct curvature is very `very small.

In the manufacture of a comparatively large reecting button of the type referred to above, such as is necessary where a large amount ofreected light is required, the shrinkage orother distortion of the large massof molten glass before it solidifles is suiiicient to Ycause such adegree of inaccuracy in the curvature of oneor more of the lens surfaces as to render the button thickness of glass this absorption of light within the glass reector button becomes appreciable. I have discovered a way of making an autocol` limating reector of the aloovecharacter which will have lightI absorption characteristics notfa'p'- preciably differentfrom` those ofa Clear glass;

reflector andyet will reflect red (or any'qother desired color). This is accomplished by; forming the reector button df clear glass and then/molding a thin film-like layerof colo the back reflecting surfacethereof. This thin layer imparts the necessary ycolbfrf't-o7 'theA reflected light and, because lof its extremethinness," ab sorbs substantially K no` light. ,'Th" i Vleaf" glass reflector button maybe moldedtc""'lcrvatu're approximately` but not quite the requisite shape,

red-l` glass over the differencel requiring a building up ofthe glass rather than grinding down of the same, and the colored glass may constitute the lm which builds up this approximately correctly shaped through a mold showing one stage in the process of manufacture of a lens in accordance with the present invention, the mold parts being shown in the open position; y

Figure 2 shows, to an enlarged scale, th'e mold parts of Figure 1 in their closed position;

Figure 3 is a plan view of a lens embodying the present invention;

Figure 4 is a sectional view taken along the lined-4 of Figure 3; n f

Figure 5 shows one step in the process of -molding a composite lens of which a lens such as shown in Figure 4 is a part, the mold parts being shown in the open position; Figure 6 is a view similar to Figure 5 and showing the mold parts in their closed position; and

Figure 7 is a longitudinal sectional view through an automobiletail lamp lens embodying the present invention.

An explanation will nowbe given of the present invention as applied to -an auto collimating reflector button of the type illustrated, for instance, in Figure 3-of the patent to Chretien, Reissue No. 19,070.- The ultimately finished reflector button is indicated by the `reference numeral I and conation from the correct curvatures will cause thev reflected light to deviate from the incident light an amount such that at a distance of three hundred feet the lens cannot be used `for thev purposes intended. It is therefore necessary to have a high degree of precision of curvature of the surfaces 3 and 4.j When large reflectorsfof the type thus far described are molded, one of the surfaces 3 or I can be molded to exactly the requisite curvature but both surfaces cannot be so molded. This is due to the fact that as the molten glass within the mold cools, and before `solidication takes place, there is shrinkage of the glass so that the mass of molten glass doe's not continue to illl vthe mold. The 'molten glass remains in intimate contact with the bottom of the mold, thus assuring a correct curvature for the bottom surface 3, as determined -by the mold shape, but it shrinks away from the topof the mold. Once the mass of molten glass has shrunk away from the top of the mold, there is nothing to confine the mass .of semi-solid glass to the requisite curvature at sists ofr a body of glass 2 of a generally tubular shape, although it may be somewhat tapered to be of larger diameter at one end thai at the other. The body of glass is constructed to reflect light in the form of a beamv substantially parallel to the'incident beam but having av very slight spread. For this purpose the "reflecting button has a front sphericalsurface 3 arid aspherically curved rear surface 4, both surfaces being of dif- Yferent radii of' curvature and having their centers on the same optical axis,`towit: on the optical axis indicated by the center line 5. The rear curved surface is silvered,` or'covered with reflecting metal 6, so that light vstriking the reflecting button at' the curved surface 3 and passing through the body of glass to the re'ar surface 6 Willbe reflected frcmthat surfaceback towards the surface 3 and thence out of the reflecting button.' .The shapes of the surfaces 3 and 4 and their distances apart are such as to produce an auto c'ollim'ating reflector. Therequisite shapes forftheispherical surfaces 3 and 4- and their distancesifa'parain order to produce-an autocollimating! effect,'m'ay be determined-in a manner known'f-inthe art,` as disclosed; for iins tance,`in the. 'ieis'suepatent to Chretien abovel'r'eferred to.'

-xpLightfstriking the surfa'c3 follows substanin-Figure 4, and `is reflected Ifrom the surface 6 and` emanates from the curved surface 3 along the top, and therefore the top surface can be only of approximately the requisite curvature. In'such practice it is necessary, after. the molding operation, to grind the top curved surface down to the requisite shape. This necessarily greatly increases the cost of production of the lens.

In accordance with the teachings of the present invention the body of glass 2 is made in any desired manner, as by casting. The rear reflecting surface is made so that it is necessary to build it up to the requisite shape rather than to grind it down to the requisite shape. Thecast or otherwise formed reflector button, having the desired shape of curvature at thebottom 3; and approximately but not quite exactly the required shape of the top surf-ace, is then placed in a mold, the female part of which is indicated at f I0 in Figure 1. While the body of glass 2 is quite hot but in the solid stage, a thin layer or film of molten glass 9 is molded over the top surface of the reflector button. The body of molten glass is dropped onto the reflector button and then a male ldie II, having the curvature I2V required for forming the curved surface of the lens, is brought down upon the mass of molten glass which is in contact with the hot preformed body of glass 2, and molds the layer of glass 9 to the requisite shape. In Figure 2 there has been illustrated, on a very much enlarged scale, the male and female dies in their closed position.- The thickness of the layer or film of glass 9 has been somewhat exaggerated for illustrative purposes, since actually it may be' only of the order of a few thousandths of an inch thick, or as 4much thicker in places or throughout as Ais'necessary.

' InvFigure 2 there is illustrated the top surface lrtially :along the paths indicated bythe arrows `minum` or other paint as is known in the art.

Il of the precast block 2; The area between the surface I5 andthe surface I2 illustrates the extent of. deviation of the surface I4 from' the requisite surface. Due to the .fact that the glass button 2 is preheated, 'the' body of glass at S fuses with the body of glass 2 to form one'ntegral mass of glass.V As the body of glass '9 cools, and before ,it'solidi`es,' there will be some shrinkage. 'f1-Iow- -ever, the amount of this shrinkage is necessarily very small since the total -volume of the molten glass 9- is small. Therefore the ultimately cast surfacewill be of the shape of the curved sur-A face `I2 of the male die. This surface requires no further grinding. The surface may then be y silvered, as indicated at 6, and the silvered layer may be protected by an outer covering of alubutton is made of colored glass there is an appreciable absorption of the white light as it passes through the comparatively thick body of glass.

In order to reduce its absorption themainbody` of glass 2 may be clear glass and the thin layerl 9 may -be of colored glass to impart the necessary color to the reflected beam. If the reflector button is to be used in` an automobile tail lamp the preferred color for the layer 9 is red, the rest of the body 2 being clear glass; f Reference may now be had more particularly to Figures and 6 wherein I illustrate one manner of making an automobile tail lamp lens having an autocollimating reflector button molded in place. In these figures the bottom mold part is indicated at I5, and the plunger or movable part is indicated at I6. A stripper ring I1 nts into a correspondingly shaped cavity in the mold part I5 in the same manner as was previously described in -connection with Figure 1, and-the ring I'I is then positioned on the mold. The reflector button 2 is at an elevated temperature somewhat less than themaximum temperature permissible without causing such softening of the glass as will result in a flow thereof. The temperature is as low as is -practical without causing cracking of the glass in the casting or subsequent cooling. Thereafter a body of red or ruby colored glass in molten form, indicated at I8, is dropped into the mold, and the top or male die member is brought down to mold the tail lamp lens. This male member is of the necessary shape to form the interior surface of the tail lamp lens in the manner required. It includes a slidable plunger having a spherically curved portion I2' which forms the thin layer over the top-of the reflector button 2 to brin-g the curvature and location of the curved portion I4 exactly tothe curvature and location required in the autocollimating lens. rAt the same time a m-ass of glass is formed around the reflector button 2, which mass of glass and thin layer 9 fuse to the glass 2, thereby forming one integral body o'f glass. Since the glass I8 is ruby colored the layer 9 imparts the requisite color to the reflected light emanating from the autooolllmating body of glass 2. The layer 9 may be of a thickness of the order of 0.175 inch to impart the requisite color to the reflected light, the thickness varying in places depending upon the amount of deviation of the surface I4 from the requisite shape and location.

a main body of glass I8 of ruby color. 'Ihe body of glass I8 may have the usual Fresnel lens rings I9 for directing light from an electric light bulb .l of the tail light, indicated at 22, in a generally trated in Figure 4, with the film of glass 9 al-` ready formed in place. However, since the tlailv horizontal direction. The rear surface of the refiector button I has a silver layer I formed thereon, which layer is protected by an outer covering of aluminum or other paint.

In m-aking the automobiletail lamp lens it is possible to use a reflector button,'such as is illuslamp lens is to be cast with the reflector button in place the operation for casting the lens may be made to include the operation of forming the thin layer 9 on the reflecting button to bring the surface of the precast. or otherwise formed reflector button up to the desired shape and with the surface 4 at exactly the correct distance from the surface 3.

'I'he curved surface I2 constitutes the bottom of a plunger 20 mounted in the male die I6 and slidable therein. A stop 2| is integral with the plunger 20 and slides within an elongated slot in the plunger I6. Adjustable screws 22 are threaded. through the stop 2| and lockedin place by locknuts 23. 'I'he screws 22 `are adjusted in the stop 2l so that when the bottoms 'of the screws 22' engage the top surface of the stripper ring I'I the bottom surface I2( of the plunger is exactly the requisite distance from the curved surface 3. Thereafter further descent of the male plunger I6 results in no movement of the plunger 28.but permits the male die to descend to press the glass I8 to the requisite shape. Any excess glass in the body of glass I8 will result in a slightly greaterthickness of the molded lens but will not affect the distance between the curved surface I2 and the curved surface 3..l A number of heavy springs 25 are provided for pressing the plunger '20 towards its lowermost position in the male die so that when the screws 22' abut against the top of the ring I1 and limit further descent of the plunger 28, a further downward movement of the die IEresults inthe compression of the powerful springs 25 so that the pressure exerted by the die I6 upon the body of molten glass cannot possibly raise the plunger glass body I8.

In Figure '7 I have illustrated a sectional view In compliance with the requirements of the .patent statutes I have here shown and described a preferred embodiment of my invention. It is,

however, to be understood that the invention is not limited to the precise construction here shown, the same being merely illustrative of the principles of the invention. What I consider new and desire to secure by Letters Patent is 1. A light transmitting and reflecting signalling lamp lens having a main body portion adapt- .ed to transmit light therethrough from a light source and an insert adapted to reflect light along a path substantially parallel to the incident beam, said body portion and insert being, of different kinds of glass, said insert comprising a preformed mass extending into and integrally united at its periphery with the body portion, said body portion having joined thereto a layer of glass overlying the insert and integrally united therewith over a substantial part of its area, the

' a path substantially parallel to the incident beam,

said body portion and insert being of different kinds of glass, said insert comprising a preformed mass extending into and integrally united atV its periphery with the body portion, said body portion having joined thereto av layer of glass overlying the insert and integrally united therewith over a substantial part of its area, the outer surface of said layer and the exposed opposite surface of the insert being of the necessary curvature and spacing to constitute an autocollimating reflector, said insert being of clear glass and said overlying layer being of red glass of substantially less thickness than the clear glass but suiilciently thick to impart a distinctly recl color to reflected white light.

3. A signal lamp lens comprising a main body of a danger indicating color and an insert comprising a bodyA of material having different light transmitting characteristics than that of the material of the main body andsurrounded by the main body, said two bodies being united along the periphery of the insert to form one integral structure and in addition said first body having joined thereto a layer of the material of which it is made which layer overlies one face of the inaasmoi" f portion and having a layer of lens material of the first portion overlying the insert and integrally united therewith over at least a substantial part of its area. said lens and insert and overlying layer being of light-pervious glass-like material and said insert being of different color than that of the ilrstfportion and said overlying layer on ythe insert imparting a characteristic color-to light reflected from the insert distinctly different from the color of the insert itself.

5. A light transmitting and reecting signal lamp lens having a portion adapted to transmit light therethrough from alight source and a portion adapted to reect light along a. path substantially parallel to the incident beam, said second portion comprising a preformed body extending into and integrally united at its periphery with the iirst portion, and said iirst portion including a layer of lens material overlying the insert and integrally united therewith over at least a substantial part of its area, the iirst portion being of colored light-pervious glass-like sert and is united thereto over at least a substantial `portion of its area, said insert, together with its overlying layer having surfaces formed to reflect light from a distant source in the general direction of the light source.

4. A light transmitting reflecting signal lamp lens having a portion adapted to transmit light therethrough from a light source and a portion adapted to reiiect light along a path substantially parallel to the incident beam, said second portion comprising a preformed body extending into and integrally united at its periphery Awith the ilrst material yand the insert being of clear lightprevious glass-like material whereby the overlying layer imparts its color to light reected by the insert, the front face of the insert and the rear surface ofthe overlying layer being both curved and of such curvature and spacing from one another to constitute an autocollimating .reflector.

6. An automobile signal lamp lens comprising a body of colored light-pervious glass for transmitting light from the interior of the lamp, an insert of clear glass extending into the colored glass but not through the same, whereby said colored glass overlies a surface of the insert which is opposite the exposed surface of the clear glass, the exposed surface of the insert and the opposite outer surface of the colored rglass layer -being of such relative curvature and spacing as to constitute a reector-lens to reflect incident light along a path substantially parallel to the path of the incident lbeam but with a slight spread, and a layer of light reflecting material on the surface of thereflector lens which is on the inner side of the lamp lens.

JAMES A. MOREHEAD. 

